Solar cell structure including a plurality of concentrator elements with a notch design and predetermined radii and method

ABSTRACT

A solar cell concentrator structure includes a first concentrator element having a first aperture region and a first exit region including a first back surface region and a first corner region. The structure also includes a second concentrator element integrally formed with the first concentrator element. The second concentrator element includes a second aperture region and a second exit region-including a second back surface region and a second corner region. Additionally, the structure includes a first radius of curvature of 0.10 mm and less characterizing the first corner structure and the second corner structure, a first coupling region between the first exit region and a first surface region of a first photovoltaic device. The structure further includes a second radius of curvature of 0.10 mm and less characterizing a region between the first concentrator element and the second concentrator element.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a continuation-in-part application claiming priorityto U.S. patent application Ser. No. 12/423,806, filed Apr. 15, 2009,which claims priority to U.S. application Ser. No. 12/060,769, filedApr. 1, 2008, which claims priority to U.S. Provisional Application No.61/019,135, filed Jan. 4, 2008, and U.S. Provisional Application No.60/969,949, filed Sep. 5, 2007. U.S. patent application Ser. No.12/423,806 also claims priority to U.S. patent application Ser. No.12/360,078, filed Jan. 26, 2009. U.S. patent application Ser. No.12/423,806 further claims priority to U.S. patent application Ser. No.11/695,566, filed Apr. 2, 2007. U.S. patent application Ser. No.12/423,806 is related to U.S. patent application Ser. Nos. 11/445,933,filed Jun. 2, 2006 and 12/200,921, filed Apr. 14, 2009. All of theseapplications are commonly assigned and incorporated by reference hereinfor all purposes.

BACKGROUND OF THE INVENTION

The present invention relates generally to solar energy techniques. Inparticular, the present invention provides a method and resulting devicefabricated from a plurality of concentrating elements respectivelycoupled to a plurality of photovoltaic regions. More particularly, thepresent method and structure are directed to a notch structure providedbetween a pair of concentrating elements. In a specific embodiment, thenotch structure is implemented to improve efficiency of the multipleconcentrator structure. Merely by way of example, the invention has beenapplied to solar panels, commonly termed modules, but it would berecognized that the invention has a much broader range of applicability.

As the population of the world increases, industrial expansion has ledto an equally large consumption of energy. Energy often comes fromfossil fuels, including coal and oil, hydroelectric plants, nuclearsources, and others. As merely an example, the International EnergyAgency projects further increases in oil consumption, with developingnations such as China and India accounting for most of the increaseAlmost every element of our daily lives depends, in part, on oil, whichis becoming increasingly scarce. As time further progresses, an era of“cheap” and plentiful oil is coming to an end. Accordingly, other andalternative sources of energy have been developed.

Concurrent with oil, we have also relied upon other very useful sourcesof energy such as hydroelectric, nuclear, and the like to provide ourelectricity needs. As an example, most of our conventional electricityrequirements for home and business use come from turbines run on coal orother forms of fossil fuel, nuclear power generation plants, andhydroelectric plants, as well as other forms of renewable energy. Oftentimes, home and business use of electrical power has been stable andwidespread.

Most importantly, much if not all of the useful energy found on theEarth comes from our sun. Generally all common plant life on the Earthachieves life using photosynthesis processes from sun light. Fossilfuels such as oil were also developed from biological materials derivedfrom energy associated with the sun. For human beings including “sunworshipers,” sunlight has been essential. For life on the planet Earth,the sun has been our most important energy source and fuel for modernday solar energy.

Solar energy possesses many characteristics that are very desirable!Solar energy is renewable, clean, abundant, and often widespread.Certain technologies developed often capture solar energy, concentrateit, store it, and convert it into other useful forms of energy.

Solar panels have been developed to convert sunlight into energy. Asmerely an example, solar thermal panels often convert electromagneticradiation from the sun into thermal energy for heating homes, runningcertain industrial processes, or driving high grade turbines to generateelectricity. As another example, solar photovoltaic panels convertsunlight directly into electricity for a variety of applications. Solarpanels are generally composed of an array of solar cells, which areinterconnected to each other. The cells are often arranged in seriesand/or parallel groups of cells in series. Accordingly, solar panelshave great potential to benefit our nation, security, and human users.They can even diversify our energy requirements and reduce the world'sdependence on oil and other potentially detrimental sources of energy.

Although solar panels have been used successfully for certainapplications, there are still certain limitations. Solar cells are oftencostly. Depending upon the geographic region, there are often financialsubsidies from governmental entities for purchasing solar panels, whichoften cannot compete with the direct purchase of electricity from publicpower companies. Additionally, the panels are often composed of siliconbearing wafer materials. Such wafer materials are often costly anddifficult to manufacture efficiently on a large scale. Availability ofsolar panels is also somewhat scarce. That is, solar panels are oftendifficult to find and purchase from limited sources of photovoltaicsilicon bearing materials. These and other limitations are describedthroughout the present specification, and may be described in moredetail below.

From the above, it is seen that techniques for improving solar devicesis highly desirable.

BRIEF SUMMARY OF THE INVENTION

The present invention relates generally to solar energy techniques. Inparticular, the present invention provides a method and resulting devicefabricated from a plurality of concentrating elements respectivelycoupled to a plurality of photovoltaic regions. More particularly, thepresent method and structure are directed to a notch structure providedbetween a pair of concentrating elements. In a specific embodiment, thenotch structure is implemented to improve efficiency of the multipleconcentrator structure. Merely by way of example, the invention has beenapplied to solar panels, commonly termed modules, but it would berecognized that the invention has a much broader range of applicability.

In a specific embodiment, the present invention provides a solar cellconcentrator structure. The solar cell concentrator structure includes afirst concentrator element. The first concentrator element includes afirst aperture region and a first exit region. The first exit regionincludes a first back surface region and a first corner region. Thesolar cell concentrator structure further includes a second concentratorelement integrally formed with the first concentrator element. Thesecond concentrator element includes a second aperture region and asecond exit region. The second exit region includes a second backsurface region and a second corner region. Additionally, the solar cellconcentrator structure includes a first radius of curvature of about0.25 mm and less characterizing the first corner structure and thesecond corner structure. In certain embodiments, the first radius ofcurvature is 0.10 mm to 0.001 mm, or 0.10 mm to 0.005 mm, 0.15 mm to0.005 mm, or 0.15 mm to 0.001 mm, or 0.25 mm to 0.001 mm, or 0.25 mm to0.005 mm. The solar cell concentrator structure also includes a firstcoupling region between the first exit region and a first surface regionof a first photovoltaic device and a second coupling region between thesecond exit region and a second surface region of a second photovoltaicdevice. Moreover, the solar cell concentrator structure includes aseparation region provided between the first concentrator element andthe second concentrator element. The separation region is characterizedby a width separating the first exit region from the second exit region.Furthermore, the solar cell concentrator structure includes a secondradius of curvature of about 0.15 mm and less characterizing a regionbetween the first concentrator element and the second concentratorelement, a triangular shaped region including an apex defined by theradius of curvature and a base defined by the separation region, and arefractive index of about 1 characterizing the triangular region.

In another specific embodiment, the invention provides a solar moduleconcentrator structure. The solar module concentrator structure includesa plurality of elongated concentrating units. Each of the plurality ofelongated concentrating units comprises a concentrator element. Theconcentrator element includes an aperture region and an exit region. Theexit region includes a back surface region and a corner structure. Eachof the plurality of elongated concentrating units also includes a radiusof curvature of about 0.25 mm and less characterizing the cornerstructure and a coupling region between the exit region and aphotovoltaic region.

In yet another specific embodiment, the present invention provides asolar cell concentrator structure. The solar cell concentrator structureincludes a piece of optical material characterized by a first spatialdirection and a second spatial direction. The first spatial direction isnormal to the second spatial direction. The solar cell concentratorstructure further includes a first concentrator element and a secondconcentrator element provided within a first portion of the piece ofoptical material and a second portion of the piece of optical material,respectively, defined along the second spatial direction. Additionally,the solar cell concentrator structure includes an aperture regionprovided on a first surface region of the piece of optical material. Theaperture region is adapted to allow electromagnetic radiation to beilluminated thereon. The solar cell concentrator structure also includesan exit region provided on a second surface region of the piece ofoptical material. The exit region is adapted to allow electromagneticradiation to be outputted and is characterized by a corner region havinga first radius of curvature of about 0.25 mm and less. Moreover, thesolar cell concentrator structure includes a separation region providedbetween the first concentrator element and the second concentratorelement. The separation region is characterized by a width within avicinity of the exit region. Furthermore, the solar cell concentratorstructure includes a radius of curvature of about 0.15 mm and lesswithin a predetermined depth of the piece of optical material. Theradius of curvature is provided between the first concentrator elementand the second concentrator element.

In an alternative embodiment, the present invention provides a methodfor manufacturing a solar cell. The method includes a step of providinga solar concentrator structure. The structure includes a firstconcentrator element with a first aperture region and a first exitregion and a second concentrator element integrally formed with thefirst concentrator element. The second concentrator element includes asecond aperture region and a second exit region. The solar concentratorstructure also includes a separation region provided between the firstconcentrator element and the second concentrator element. The separationregion is characterized by a width separating the first exit region fromthe second exit region. Additionally, the solar concentrator structureincludes a radius of curvature of about 0.15 mm and less characterizinga region between the first concentrator element and the secondconcentrator element and a triangular region including an apex formed bythe radius of curvature and a base formed by the separation region.Moreover, the solar concentrator structure includes a refractive indexof about 1.0 characterizing the triangular region. The method furtherincludes a step of coupling a first photovoltaic region to the firstconcentrator element and a step of coupling a second photovoltaic regionto the second concentrator element.

In another alternative embodiment, the invention provides a solarconcentrator structure. The solar concentrator structure includes athickness of material characterized along a first spatial directionincluding at least a first concentrator element and a secondconcentrator element provided within a first portion of the thickness ofmaterial and a second portion of the thickness of material defined alonga second spatial direction, the first concentrator element and thesecond concentrator element having a thickness of 5 mm to 7 mm. Thesolar concentrator structure also includes an aperture region providedon a first surface region of the thickness of material. The apertureregion is adapted to allow electromagnetic radiation to be illuminatedthereon. Additionally, the solar concentrator structure includes an exitregion provided on a second surface region of the thickness of material.The exit region is adapted to allow electromagnetic radiation to beoutputted. Moreover, the solar concentrator structure includes aseparation region provided between the first concentrator element andthe second concentrator element. The separation region is characterizedby a width within a vicinity of the exit region. Furthermore, the solarconcentrator structure includes a radius of curvature of about 0.15 mmand less within a predetermined depth of the thickness of material.

Many benefits are achieved by way of the present invention overconventional techniques. For example, the invention provides for animproved solar cell concentrator structure for manufacture of solarmodule. Such solar concentrator structure uses a single piece ofpolymeric or glass webbing or a combination integrally including aplurality of elongated concentrating units each comprising a geometriclight concentrator element coupled to one of a plurality of photovoltaicstrips. In a preferred embodiment, the geometric light concentratorelement has a geometric concentration characteristic with an aperture toexit ratio in a range from about 1.8 to about 4.5 and the exit regionincludes two exit notches with a radius of curvature of about 0.25 mmand less characterizing the corresponding two corner structures. Inanother preferred embodiment, between the exit region of theconcentrator element and a photovoltaic strip there is a coupling regionthat is configured to have its refractive index matched and accommodatethe radius of the exit notches. The use of concentrator according to thepresent invention helps the solar conversion module having lessphotovoltaic material per surface area (e.g., 80% or less, 50% or less)than conventional solar panel module. Depending upon the embodiment, oneor more of these benefits may be achieved. These and other benefits willbe described in more detail throughout the present specification andmore particularly below.

Various additional objects, features and advantages of the presentinvention can be more fully appreciated with reference to the detaileddescription and accompanying drawings that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a simplified diagram of a solar cell according to anembodiment of the present invention;

FIG. 2 is a simplified diagram of solar cell concentrating elementsaccording to an embodiment of the present invention;

FIG. 2A is a simplified side-view diagram of solar cell concentratingelements according to an embodiment of the present invention;

FIG. 3 is a simplified diagram of a plurality of notch structures for asolar cell concentrator according to an embodiment of the presentinvention;

FIG. 4 is a more detailed diagram of a notch structure for a solar cellconcentrator according to an embodiment of the present invention;

FIG. 5 is a plot of irradiation loss as a function of notch structuresize according to an embodiment of the present invention;

FIG. 6 is a simplified diagram of a coupling region provided between anexit region of an concentrator element and a photovoltaic regionaccording to an embodiment of the present invention;

FIG. 7 is a plot of concentration ratio as a function of cornerstructure size of a solar cell concentrator according to an embodimentof the present invention; and

FIG. 8 is a plot of irradiation loss as a function of corner structureof the solar concentrator according to an embodiment of the presentinvention.

DETAILED DESCRIPTION OF THE INVENTION

According to the present invention, techniques related to solar energyare provided. In particular, the present invention provides a method andresulting device fabricated from a plurality of concentrating elementsrespectively coupled to a plurality of photovoltaic regions. Moreparticularly, the present method and structure are directed to a notchstructure provided between a pair of concentrating elements. In aspecific embodiment, the notch structure is implemented to improveefficiency of the multiple concentrator structure. Merely by way ofexample, the invention has been applied to solar panels, commonly termedmodules, but it would be recognized that the invention has a muchbroader range of applicability.

FIG. 1 is a simplified diagram of a solar cell according to anembodiment of the present invention. This diagram is merely an example,which should not unduly limit the scope of the claims herein. One ofordinary skill in the art would recognize other variations,modifications, and alternatives. As shown is an expanded view of thepresent solar cell device structure, which includes various elements.The device has a back cover member 101, which includes a surface areaand a back area. The back cover member also has a plurality of sites,which are spatially disposed, for electrical members, such as bus bars,and a plurality of photovoltaic regions. Alternatively, the back covercan be free from any patterns and is merely provided for support andpackaging. Of course, there can be other variations, modifications, andalternatives.

In a preferred embodiment, the device has a plurality of photovoltaicstrips 105, each of which is disposed overlying the surface area of theback cover member. In a preferred embodiment, the plurality ofphotovoltaic strips corresponds to a cumulative area occupying a totalphotovoltaic spatial region, which is active and converts sunlight intoelectrical energy.

An encapsulating material 115 is overlying a portion of the back covermember. That is, an encapsulating material forms overlying the pluralityof strips, and exposed regions of the back cover, and electricalmembers. In a preferred embodiment, the encapsulating material can be asingle layer, multiple layers, or portions of layers, depending upon theapplication. In alternative embodiments, as noted, the encapsulatingmaterial can be provided overlying a portion of the photovoltaic stripsor a surface region of the front cover member, which would be coupled tothe plurality of photovoltaic strips. Of course, there can be othervariations, modifications, and alternatives.

In a specific embodiment, a front cover member 121 is coupled to theencapsulating material. That is, the front cover member is formedoverlying the encapsulate to form a multilayered structure including atleast the back cover, bus bars, plurality of photovoltaic strips,encapsulate, and front cover. In a preferred embodiment, the front coverincludes one or more concentrating elements, which concentrate (e.g.,intensify per unit area) sunlight onto the plurality of photovoltaicstrips. That is, each of the concentrating elements can be associatedrespectively with each of or at least one of the photovoltaic strips.

Upon assembly of the back cover, bus bars, photovoltaic strips,encapsulate, and front cover, an interface region is provided along atleast a peripheral region of the back cover member and the front covermember. The interface region may also be provided surrounding each ofthe strips or certain groups of the strips depending upon theembodiment. The device has a sealed region and is formed on at least theinterface region to form an individual solar cell from the back covermember and the front cover member. The sealed region maintains theactive regions, including photovoltaic strips, in a controlledenvironment free from external effects, such as weather, mechanicalhandling, environmental conditions, and other influences that maydegrade the quality of the solar cell. Additionally, the sealed regionand/or sealed member (e.g., two substrates) protect certain opticalcharacteristics associated with the solar cell and also protects andmaintains any of the electrical conductive members, such as bus bars,interconnects, and the like. Of course, there can be other benefitsachieved using the sealed member structure according to otherembodiments.

In a preferred embodiment, the total photovoltaic spatial regionoccupies a smaller spatial region than the surface area of the backcover. That is, the total photovoltaic spatial region uses less siliconthan conventional solar cells for a given solar cell size. In apreferred embodiment, the total photovoltaic spatial region occupiesabout 80% and less of the surface area of the back cover for theindividual solar cell. Depending upon the embodiment, the photovoltaicspatial region may also occupy about 70% and less or 60% and less orpreferably 50% and less of the surface area of the back cover or givenarea of a solar cell. Of course, there can be other percentages thathave not been expressly recited according to other embodiments. Here,the terms “back cover member” and “front cover member” are provided forillustrative purposes, and not intended to limit the scope of the claimsto a particular configuration relative to a spatial orientationaccording to a specific embodiment. Further details of each of thevarious elements in the solar cell can be found throughout the presentspecification and more particularly below.

In a specific embodiment, the present invention provides a packagedsolar cell assembly being capable of stand-alone operation to generatepower using the packaged solar cell assembly and/or with other solarcell assemblies. The packaged solar cell assembly includes rigid frontcover member having a front cover surface area and a plurality ofconcentrating elements thereon. Depending upon applications, the rigidfront cover member consists of a variety of materials. For example, therigid front cover is made of polymer material. As another example, therigid front cover is made of transparent polymer material having areflective index of about 1.4 or 1.42 or greater. According to anexample, the rigid front cover has a Young's Modulus of a suitablerange. Each of the concentrating elements has a length extending from afirst portion of the front cover surface area to a second portion of thefront cover surface area. Each of the concentrating elements has a widthprovided between the first portion and the second portion. Each of theconcentrating elements having a first edge region coupled to a firstside of the width and a second edge region provided on a second side ofthe width. The first edge region and the second edge region extend fromthe first portion of the front cover surface area to a second portion ofthe front cover surface area. The plurality of concentrating elements isconfigured in a parallel manner extending from the first portion to thesecond portion.

It is to be appreciated that embodiment can have many variations. Forexample, the embodiment may further includes a first electrode memberthat is coupled to a first region of each of the plurality ofphotovoltaic strips and a second electrode member coupled to a secondregion of each of the plurality of photovoltaic strips.

As another example, the solar cell assembly additionally includes afirst electrode member coupled to a first region of each of theplurality of photovoltaic strips and a second electrode member coupledto a second region of each of the plurality of photovoltaic strips. Thefirst electrode includes a first protruding portion extending from afirst portion of the sandwiched assembly and the second electrodecomprising a second protruding portion extending from a second portionof the sandwiched assembly.

In yet another specific embodiment, the present invention provides asolar cell apparatus. The solar cell apparatus includes a backsidesubstrate member comprising a backside surface region and an innersurface region. Depending upon application, the backside substratemember can be made from various materials. For example, the backsidemember is characterized by a polymer material.

In yet another embodiment, the present invention provides a solar cellapparatus that includes a backside substrate member. The backsidesubstrate member includes a backside surface region and an inner surfaceregion. The backside substrate member is characterized by a width. Forexample, the backside substrate member is characterized by a length ofabout eight inches and less. As an example, the backside substratemember is characterized by a width of about 8 inches and less and alength of more than 8 inches. Of course, there can be other variations,modifications, and alternatives. Further details of the solar cellassembly can be found in U.S. patent application Ser. No. 11/445,933,commonly assigned, and hereby incorporated by reference herein.

FIG. 2 is a simplified diagram of solar cell concentrating elementsaccording to an embodiment of the present invention. This diagram ismerely an example, which should not unduly limit the scope of the claimsherein. One of ordinary skill in the art would recognize othervariations, modifications, and alternatives. As shown, each of theconcentrating elements for the strip configuration includes atrapezoidal shaped member. Each of the trapezoidal shaped members has abottom surface 201 coupled to a pyramidal shaped region 205 coupled toan upper region 207. The upper region is defined by surface 209, whichis co-extensive of the front cover. Each of the members is spatiallydisposed and in parallel to each other according to a specificembodiment. Here, the term “trapezoidal” or “pyramidal” may includeembodiments with straight or curved or a combination of straight andcurved walls according to embodiments of the present invention.Depending upon the embodiment, the concentrating elements may be on thefront cover, integrated into the front cover, and/or be coupled to thefront cover according to embodiments of the present invention. Furtherdetails of the front cover with concentrating elements are provided moreparticularly below.

In a specific embodiment, a solar cell apparatus includes a shapedconcentrator device operably coupled to each of the plurality ofphotovoltaic strips. The shaped concentrator device has a first side anda second side. In addition, the solar cell apparatus includes anaperture region provided on the first side of the shaped concentratordevice. As merely an example, the concentrator device includes a firstside region and a second side region. Depending upon application, thefirst side region is characterized by a roughness of about 100nanometers or 120 nanometers RMS and less, and the second side region ischaracterized by a roughness of about 100 nanometers or 120 nanometersRMS and less. For example, the roughness is characterized by a dimensionvalue of about 10% of a light wavelength derived from the apertureregions. Depending upon applications, the backside member can have apyramid-type shape.

As an example, the solar cell apparatus includes an exit region providedon the second side of the shaped concentrator device. In addition, thesolar cell apparatus includes a geometric concentration characteristicprovided by a ratio of the aperture region to the exit region. The ratiocan be characterized by a range from about 1.8 to about 4.5. The solarcell apparatus also includes a polymer material characterizing theshaped concentrator device. The solar cell apparatus additionallyincludes a refractive index of about 1.45 and greater characterizing thepolymer material of the shaped concentrator device. Additionally, thesolar cell apparatus includes a coupling material formed overlying eachof the plurality of photovoltaic strips and coupling each of theplurality of photovoltaic regions to each of the concentrator devices.For example, the coupling material is characterized by a suitableYoung's Modulus.

As merely an example, the solar cell apparatus includes a refractiveindex of about 1.45 and greater characterizing the coupling materialcoupling each of the plurality of photovoltaic regions to each of theconcentrator device. Depending upon application, the polymer material ischaracterized by a thermal expansion constant that is suitable towithstand changes due to thermal expansion of elements of the solar cellapparatus.

For certain applications, the plurality of concentrating elements has alight entrance area (A1) and a light exit area (A2) such that A2/A1 is0.8 and less. As merely an example, the plurality of concentratingelements has a light entrance area (A1) and a light exit area (A2) suchthat A2/A1 is 0.8 and less, and the plurality of photo voltaic stripsare coupled against the light exit area. In a preferred embodiment, theratio of A2/A1 is about 0.5 and less. For example, each of theconcentrating elements has a height of 7 mm or less. In a specificembodiment, the sealed sandwiched assembly has a width ranging fromabout 100 millimeters to about 210 millimeters and a length ranging fromabout 100 millimeters to about 210 millimeters. In a specificembodiment, the sealed sandwiched assembly can even have a length ofabout 300 millimeters and greater. As another example, each of theconcentrating elements has a pair of sides. In a specific embodiment,each of the sides has a surface finish of 100 nanometers or less or 120nanometers and less RMS. Of course, there can be other variations,modifications, and alternatives.

Referring now to FIG. 2A, the front cover has been illustrated using aside view 201, which is similar to FIG. 2. The front cover also has atop-view illustration 210. A section view 220 from “B-B” has also beenillustrated. A detailed view “A” of at least two of the concentratingelements 230 is also shown. Depending upon the embodiment, there can beother variations, modifications, and alternatives.

Depending upon the embodiment, the concentrating elements are made of asuitable material. The concentrating elements can be made of a polymer,glass, or other optically transparent materials, including anycombination of these, and the like. The suitable material is preferablyenvironmentally stable and can withstand environmental temperatures,weather, and other “outdoor” conditions. The concentrating elements canalso include portions that are coated with an anti-reflective coatingfor improved efficiency. Coatings can also be used for improving adurability of the concentrating elements. Of course, there can be othervariations, modifications, and alternatives.

In a specific embodiment, the solar cell apparatus includes a firstreflective side provided between a first portion of the aperture regionand a first portion of the exit region. As merely an example, the firstreflective side includes a first polished surface of a portion of thepolymer material. For certain applications, the first reflective side ischaracterized by a surface roughness of about 120 nanometers RMS andless.

Moreover, the solar cell apparatus includes a second reflective sideprovided between a second portion of the aperture region and a secondportion of the exit region. For example, the second reflective sidecomprises a second polished surface of a portion of the polymermaterial. For certain applications, the second reflective side ischaracterized by a surface roughness of about 120 nanometers and less.As an example, the first reflective side and the second reflective sideprovide for total internal reflection of one or more photons providedfrom the aperture region.

In addition, the solar cell apparatus includes a geometric concentrationcharacteristic provided by a ratio of the aperture region to the exitregion. The ratio is characterized by a range from about 1.8 to about4.5. Additionally, the solar cell apparatus includes a polymer materialcharacterizing the shaped concentrator device, which includes theaperture region, exit region, first reflective side, and secondreflective side. As an example, the polymer material is capable of beingfree from damaged caused by ultraviolet radiation.

Furthermore, the solar cell apparatus has a refractive index of about1.45 and greater characterizing the polymeric and/or glass material ofthe shaped concentrator device. Moreover, the solar cell apparatusincludes a coupling material formed overlying each of the plurality ofphotovoltaic strips and coupling each of the plurality of photovoltaicregions to each of the concentrator devices. The solar cell apparatusadditionally includes one or more pocket regions facing each of thefirst reflective side and the second reflective side. The one or morepocket regions can be characterized by a refractive index of about 1 tocause one or more photons from the aperture region to be reflectedtoward the exit region. To maintain good efficiency of the subjectconcentrator devices, each of the concentrating elements is separated bya region having a notch structure of a predetermined size and shapeaccording to a specific embodiment. Additionally, the exit region ofeach of the shaped concentrator device includes a corner structurehaving a first predetermined size and shape to also allow for goodefficiency of the subject concentrator devices. Further details of thenotch structures and the corner structures can be found throughout thepresent specification and more particularly below.

FIG. 3 is a simplified diagram of a plurality of notch structures andcorner structures for a solar cell concentrator 300 according to anembodiment of the present invention. This diagram is merely an example,which should not unduly limit the scope of the claims herein. One ofordinary skill in the art would recognize other variations,modifications, and alternatives. As shown, the concentrator structurehas a first concentrator element 301, which includes a first apertureregion 304 and a first exit region 306. The concentrator structure alsoincludes a second concentrator element 302 integrally formed with thefirst concentrator element. In a specific embodiment, the secondconcentrator element includes a second aperture region 308 and a secondexit region 310.

In a specific embodiment, the concentrator structure has a separationregion 312 provided between the first concentrator element and thesecond concentrator element. The separation region is characterized by awidth 314 separating the first exit region from the second exit region.As shown the separation region includes a triangular shapedregion-having an apex 316 defined by a radius of curvature of 0.15 mmand less and a base defined by the separation region. In a specificembodiment, the triangular region has a refractive index of about one,which can be essentially an air gap and/or other non-solid open region.The apex of the triangular region is provided within a thickness ofmaterial 318 of the concentrator structure. Also shown in FIG. 3, eachof the concentrator elements includes a first corner structure 320 and asecond corner structure 322 in a portion of the exit region. The cornerstructure 322 is characterized by an exit radius curvature. The exitradius curvature is predetermined in conjunction with the radius ofcurvature of the apex 316 to optimize performance of the solar cell. Inaddition, the manufacturing costs, structural integrity, and/or strengthmay also be a consideration in determining the exit radius. For example,the exit radius is greater than a critical radius where the concentratorstructure is likely to crack. More detailed discuss is provide below.

FIG. 4 is a more detailed diagram of a notch structure for a solar cellconcentrator according to an embodiment of the present invention. Thisdiagram is merely an example, which should not unduly limit the scope ofthe claims herein. One of ordinary skill in the art would recognizeother variations, modifications, and alternatives. As shown in FIG. 4,the apex of the triangular region includes a notch structurecharacterized by an apex region 401 and wall regions 403. In a specificembodiment, the wall regions are straight. In certain other embodiments,the wall region may be curved. The notch structure describes a portionof a cross section of a triangular channel region provided between afirst solar concentration element and a second solar concentrationelement. The term “notch” is not intended to be limited to thespecification but should be construed by a common interpretation of theterm. In a specific embodiment, the apex region is characterized by aradius of curvature 405. In a specific embodiment, the radius ofcurvature can be greater than about 0.001 mm. In an alternativeembodiment, the radius of curvature can range from 0.05 mm to about 0.15mm. Preferably, a minimum of radius of curvature is provided to maintaina structure/mechanical integrity of the solar cell concentrator in thetemperature range of about −40 deg Celsius and 85 deg Celsius inaccordance with IEC (International Electrotechnical Commission) 61215specification according to a specific embodiment. Of course there can beother modifications, variations, and alternatives.

FIG. 5 is a more detailed diagram illustrating a corner structure 506 ofa concentrator element 502 according to an embodiment of the presentinvention. As shown, an exit region 504 is optically coupled to aphotovoltaic region 508 in a specific embodiment. In a specificembodiment, the corner structure 506 is characterized by an exit radiusof curvature 510. In a specific embodiment, the exit radius of curvaturecan be greater than about 0.001 mm. In an alternative embodiment, theexit radius of curvature can range from 0.025 to 0.15 mm. As explainedabove, the exit radius of the curvature is optimized to maintain anefficient transmission of electromagnetic radiation to the photovoltaicregion in a specific embodiment. For example, the curvature 510 isdetermined using a variety of factors, such as the refractive index(and/or other optical properties) of the concentrator element, the angleof the exit aperture 316 illustrated in FIG. 3, and/or other factors. Ofcourse there can be other variations, modifications, and alternatives.

In one embodiment, the solar concentrator can be made of materialsselected from acrylic, or diamond, or quartz, or glass, or a combinationof those materials. In a specific embodiment, the solar concentrator isfabricated using a mold having an edge radius of curvature of less than0.15 mm. The material for making the concentrator can be injectedthrough a fan gate, or a valve gate, or an extrusion filling the mold.The structural components may include a compression component and aheating component. The heating component may generate heat during themolding process via current or through an external heating source. Ofcourse there can be other variations, modifications, and alternatives.

Also shown in FIG. 6, a coupling region 602 can be provided between anexit region of a concentrator element and a photovoltaic region. Likereferences are used in the present Figure and others and not intended tobe limited. Merely for the purpose of illustration, various structuresare not drawn in scale. In a specific embodiment, the exit region isoptically coupled to the photovoltaic region using an optical couplingmaterial within the coupling region. Examples of such optical couplingmaterial can include optical grade epoxy, ethylene vinyl acetate (EVA),silicones, polyurethanes, and others. In a specific embodiment, theoptical coupling material includes polyurethanes provided in a thicknessof 0.025 to 0.25 mm. Of course one skilled in the art would recognizeother variations, modifications, and alternatives.

FIG. 7 is a plot of concentration ratio as a function of cornerstructure size of a solar cell concentrator according to an embodimentof the present invention. This diagram is merely an example, whichshould not unduly limit the scope of the claims herein. One of ordinaryskill in the art would recognize other variations, modifications, andalternatives. As shown, the vertical axis illustrates concentrationratio and the horizontal axis illustrates notch structure size or radiusof curvature. The result was obtained using a solar cell concentratorwith an entrance of 4 mm and an exit of 2 mm. The concentration ratiogenerally decreases with an increase in exit radius of curvature of thecorner structure. A corresponding plot of irradiation loss as a functionof corner structure is shown in FIG. 8. As shown, the vertical axisillustrates percent of light loss or irradiation loss and the horizontalaxis illustrates exit radius of curvature of the corner structure. Theirradiation loss generally increases with an increase of exit radius. Ina specific embodiment, the exit radius of curvature is optimized toallow for a maximum concentration ratio or a minimum scattering loss andto allow for maintaining mechanical/structural integrity of the solarcell concentrator in the temperature range between about −40 deg Celsiusand 85 deg Celsius according to IEC 61215 specifications according to apreferred embodiment.

It is also understood that the examples and embodiments described hereinare for illustrative purposes only and that various modifications orchanges in light thereof will be suggested to persons skilled in the artand are to be included within the spirit and purview of this applicationand scope of the appended claims.

1. A solar cell concentrator structure, the solar cell concentratorstructure comprising: a first concentrator element configured in a firstpyramidal shape having a first curved wall region, the firstconcentrator element including a first aperture region and a first exitregion, the first exit region including a first back surface region; asecond concentrator element configured in a second pyramidal shapehaving a second curved wall region and the second concentrator elementbeing integrally formed with the first concentrator element, the secondconcentrator element including a second aperture region and a secondexit region, the second exit region including a second back surfaceregion; a first coupling region between the first exit region and afirst surface region of a first photovoltaic device; a second couplingregion between the second exit region and a second surface region of asecond photovoltaic device; a thickness of glass material comprising thefirst concentrator element integrally formed with the secondconcentrator element, the thickness of glass being 5 mm to 7 mm; aseparation region provided between the first concentrator element andthe second concentrator element, the separation region beingcharacterized by a width separating the first exit region from thesecond exit region; a second radius of curvature characterizing a regionbetween the first concentrator element and the second concentratorelement, the second radius of curvature being less than about 0.10 mmand greater than 0.001 mm; a geometric concentration range from about1.8 to 4.5 characterizing the first concentrator element and the secondconcentrator element; a triangular shaped region including an apexdefined by the second radius of curvature and a base defined by theseparation region; and a refractive index of about 1 characterizing thetriangular region; wherein the second radius of curvature reduces ascattering effect of a portion of an incident electromagnetic radiation.2. The structure of claim 1 wherein the second exit region includes asecond corner region and the first exit region includes a first cornerregion and further comprising a first radius of curvature characterizingthe first corner structure, the first radius of curvature being lessthan 0.10 mm and greater than 0.001 mm.
 3. The structure of claim 1wherein the first concentrator element integrally formed with the secondconcentrator element are essentially a single piece of the glassmaterial.
 4. The structure of claim 1 wherein the first concentratorelement integrally formed with the second concentrator element ismolded.
 5. The structure of claim 1 wherein the first concentratorelement and the second concentrator element are characterized by arefractive index of about 1.4 and greater.
 6. The structure of claim 1wherein the first concentrator is characterized by a first truncatedpyramid shape and the second concentrator is characterized by a secondtruncated pyramid shape.
 7. The structure of claim 1 wherein thecoupling region comprises an optical coupling material.
 8. The structureof claim 1 wherein the optical coupling material comprises an opticalgrade epoxy, or ethylene vinyl acetate (EVA), or silicones, orpolyurethanes.
 9. The structure of claim 1 wherein the firstconcentrator element is optically coupled to a first photovoltaic regionand the second concentrator element is optically coupled to a secondphotovoltaic region.
 10. The structure of claim 1 wherein the secondradius of curvature is greater than an amount that causes a crack withina portion of a thickness of the glass material.
 11. A solar cellconcentrator structure, the solar cell concentrator structurecomprising: a piece of optical material made of glass characterized by afirst spatial direction and a second spatial direction, the firstspatial direction being normal to the second spatial direction; a firstconcentrator element and a second concentrator element provided within afirst portion of the piece of optical material and a second portion ofthe piece of optical material, respectively, defined along the secondspatial direction, the first concentrator element and the secondconcentrator element having a thickness of 5 mm to 7 mm; an apertureregion provided on a first surface region of the piece of opticalmaterial, the aperture region being adapted to allow electromagneticradiation to be illuminated thereon; an exit region provided on a secondsurface region of the piece of optical material; a separation regionprovided between the first concentrator element and the secondconcentrator element, the separation region being characterized by awidth; a second radius of curvature being less than about 0.10 mm andgreater than 0.001 mm within a predetermined depth of the piece ofoptical material, the second radius of curvature being provided betweenthe first concentrator element and the second concentrator element; atriangular shaped region including an apex defined by the second radiusof curvature.
 12. The structure of claim 11 wherein the piece of opticalmaterial is essentially the glass material; wherein the firstconcentrator element characterized by a first radius of curvature. 13.The structure of claim 11 wherein the second radius of curvature reducesan efficiency of the first concentrator element and the secondconcentrator element by about 50% and less.
 14. The structure of claim11 wherein the piece of optical material is characterized by arefractive index of about 1.4 and more.
 15. The structure of claim 11wherein the second radius of curvature is an apex of a triangular regionhaving a base provided within a portion of a first exit region of thefirst concentrator element and a second exit region of the secondconcentrator element.
 16. The structure of claim 11 wherein the secondradius of curvature is an apex of a triangular region having a baseprovided within a portion of a first exit region of the firstconcentrator element and a second exit region of the second concentratorelement, the triangular region having a refractive index of about 1.0.17. A solar cell concentrator structure, the solar cell concentratorstructure comprising: a first concentrator element, the firstconcentrator element including a first aperture region and a first exitregion, the first exit region including a first back surface region, thefirst concentrator element being characterized by a refractive index ofabout 1.4 and greater; a second concentrator element integrally formedwith the first concentrator element, the second concentrator elementbeing characterized by a refractive index of about 1.4 and greater, thesecond concentrator element including a second aperture region and asecond exit region, the second exit region including a second backsurface region, the first concentrator element integrally formed withthe second concentrator element being essentially a single piece ofmolded glass material, the first concentrator element being opticallycoupled to a first photovoltaic region and the second concentratorelement being optically coupled to a second photovoltaic region; athickness of 5 mm to 7 mm characterizing the first concentrator elementand the second concentrator element; a first coupling region between thefirst exit region and a first surface region of a first photovoltaicdevice, the first coupling region including an optical coupling materialcomprising an EVA material; a second coupling region between the secondexit region and a second surface region of a second photovoltaic device;a separation region provided between the first concentrator element andthe second concentrator element, the separation region beingcharacterized by a width separating the first exit region from thesecond exit region; a radius of curvature characterizing a regionbetween the first concentrator element and the second concentratorelement, the radius of curvature being about between 0.001 mm and 0.10mm; a triangular shaped region including an apex defined by the radiusof curvature and a base defined by the separation region; and arefractive index of about 1 characterizing the triangular region.